Washable, waterproof, sealable and reusable storage bags

ABSTRACT

Disclosed are embodiments of a versatile storage bag and methods of making same. The versatile storage bag may have first and second sidewalls, a double-locking closure mechanism with a first closure element extending along the first sidewall and a second closure element extending along the second sidewall, each closure element having a channel and an elongated member configured for interlocking with one another. A double-seal along three sides of the first sidewall and the second sidewall form a gusset between two seals, leaving an opening through the double-locking closure mechanism. Corner seals may be formed at the corners of the first and second sidewalls, further reinforcing the double-locking closure mechanism for an airtight and hence waterproof seal. The versatile storage bag may be made of a food-grade polyethylene vinyl acetate blend, approximately 90% or less ethylene vinyl acetate and approximately 10% or less polyethylene.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a divisional application of U.S. patent application Ser. No.14/598,475, filed Jan. 16, 2015, entitled “WASHABLE, WATERPROOF,SEALABLE AND REUSABLE STORAGE BAGS,” which claims a benefit of priorityfrom U.S. Provisional Application No. 61/928,575, filed Jan. 17, 2014,entitled “WASHABLE, WATERPROOF, SEALABLE AND REUSABLE STORAGE BAGS.”This application relates to U.S. patent application Ser. No. 14/598,511,filed Jan. 16, 2015, entitled “WASHABLE, WATERPROOF, SEALABLE ANDREUSABLE SOFT GUSSETED VOLUMIZED STORAGE BAGS,” which claims a benefitof priority from U.S. Provisional Application No. 61/928,579, filed Jan.17, 2014, entitled “WASHABLE, WATERPROOF, SEALABLE AND REUSABLE SOFTGUSSETED VOLUMIZED STORAGE BAGS.” All applications referenced in thisparagraph are incorporated by reference herein in their entireties.

TECHNICAL FIELD

This disclosure relates generally to storage containers. Moreparticularly, embodiments disclosed herein relate to lightweight,sealable, and reusable storage containers, useful in a variety ofcontainer categories, including food, travel, and organization.

BACKGROUND OF THE RELATED ART

Today's food storage containers generally fall into two classes: eitherbulky and reusable, or lightweight but designed for single-usedisposable options. The former is either a glass item that offerstoxin-free storage, but is heavy to carry, or a plastic container, thatmay have toxins and still may be too bulky for practical uses. Thelightweight alternatives are often disposable style bags with a sealedclosure, but are made of a material and/or design specific for singleuse purposes. While some customers do wash and reuse, these lightweightdisposable style bags tend to deteriorate and/or fall apart ratherquickly after first use. Furthermore, they are not designed to withstandmultiple cleanings in the dishwasher or washing machine.

Examples of various storage containers can be found in U.S. Pat. No.8,578,572, entitled “CLOSURE MECHANISM AND METHOD OF CLOSING”; U.S. Pat.No. 8,568,031, entitled “CLICKING CLOSURE DEVICE FORA RECLOSABLE BAG”;U.S. Pat. No. 8,308,021, entitled “DISPOSABLE STORAGE CONTAINER”; U.S.Pat. No. 8,469,593, entitled “RECLOSABLE BAG HAVING A PRESS TO VENTZIPPER”; U.S. Pat. No. 5,542,766, entitled “WATERPROOF CLOSURE SEAL FORBAGS, CLOTHING AND OTHER USES”, U.S. Pat. No. 8,196,269, entitled“CLOSURE MECHANISM FOR A RECLOSABLE POUCH”, U.S. Pat. No. 8,474,623,entitled “ECOLOGICAL SNACK BAG”; U.S. Pat. No. 7,857,515, entitled“AIRTIGHT CLOSURE MECHANISM FOR A RECLOSABLE POUCH”; U.S. Pat. No.8,197,139, entitled “VALVE AND VALVE STRIP FOR A RECLOSABLE CONTAINER”;and U.S. Pat. No. 8,308,021, entitled “DISPOSABLE STORAGE CONTAINER”.

These and other storage containers currently available on the marketsuffer some or all the aforementioned drawbacks and/or lack certaindesirable properties such as lightweight, flexibility, washability,sealability, reusability, durability, etc. Consequently, there is roomfor innovations and improvements in the field of storage containers.

SUMMARY OF THE DISCLOSURE

Embodiments disclosed herein are directed to lightweight, flexible,washable, sealable, reusable, reclosable, and durable storage containersand methods of manufacturing same. In some embodiments, such a storagecontainer may be referred to herein as a versatile pouch or storage bag.

In some embodiments, such a versatile storage bag can include orotherwise incorporate freshness and watertight properties desirable infood and travel storage, addressing a particular need in the art for afood grade durable, reliable, washable, and sealable storage bag.

In some embodiments, the versatile storage bag can be made of athermoplastic material such as food safe, FDA-grade polyethylene vinylacetate (PEVA) blend of ethylene vinyl acetate (EVA) and polyethylene(PE). The ratio of EVA/PE may vary from implementation toimplementation, depending upon the desired properties such as stiffness,flexibility, tear resistance, heat resistance, heat retention, etc. Insome embodiments, the ratio of EVA/PE in the material of a versatilestorage bag may range from, for instance, approximately 9 parts of EVAto one part of PE to approximately 7 parts of EVA to 3 parts of PE.Those skilled in the art will appreciate that different ratios of EVA/PEmay be used. Those skilled in the art will also appreciate that othermaterials may be used and/or added. In some embodiments, the material ofthe versatile storage bag may have a minimum thickness configured forallowing hot and cold water washing as well as for multiple reuses. Insome embodiments, the versatile storage bag can be machine washedmultiple times in high-heat, providing a highly desirable reusability.

In some embodiments, the entire versatile storage bag can be made of thesame material, including a unique closure mechanism that significantlyimproves the sealability over prior storage containers. In someembodiments, the versatile storage bag can be made of two or morematerials, with the closure mechanism of the versatile storage baghaving a first ratio of EVA/PE and a body of the versatile storage baghaving a second ratio of EVA/PE such that the body of the versatilestorage bag is more flexible than the closure mechanism.

Numerous other materials and combinations thereof may also be suitablefor implementing embodiments of a versatile storage bag disclosedherein.

In some embodiments, the closure mechanism of a versatile storage bagdisclosed herein can include a pair of closure elements located on twosides of the versatile storage bag. The first closure element mayinclude a channel and an elongated member extending along a base of thefirst closure element. The second, complementary closure element mayinclude an elongated member and a channel extending along a base of thesecond closure element. Each channel may have a cross-sectional profileresembling a pair of arms extending from a body. Each elongated membermay have a cross-sectional profile resembling a stud or post.

The cross-sectional profile of the channel is configured to allow thechannel to, when pressed, extend to each side of the elongated member tothereby lock with the elongated member. Both elongated members may havea textured or shaped surface to lock and seal in their correspondingchannels and the channels can fully and securely receive theircorresponding elongated members to lock and thereby create an airtight(and hence waterproof) seal which, in some embodiments, may be referredto as a “double-lock.”

In some embodiments, a method of making a versatile storage bag mayinclude a) manipulating a first material using a first tool to create afirst portion having at least a first closure element, the first closureelement having a channel and an elongated member extending along a baseof the first closure element; b) manipulating a second material using asecond tool to create a second portion having a flat or substantiallyflat surface; c) joining the first portion and the second portion tocreate a first sidewall with the first closure element; d) creating acomplementary first portion having a second closure element, the secondclosure element having an elongated member and a channel extending alonga base of the second closure element; e) joining the complementary firstportion and a complementary second portion to create a second sidewallwith the second closure element; f) aligning the first sidewall and thesecond sidewall such that the first closure element and the secondclosure element together form a double-locking closure mechanism; and g)forming double seals along three sides of the first sidewall and thesecond sidewall, leaving an opening through the double-locking closuremechanism.

In some embodiments, the method may further comprise forming a firstcorner seal at a first corner and a second corner seal at a secondcorner of the versatile storage bag. These corner seals can reinforcethe double-locking closure mechanism and overall strength and durabilityof the versatile storage bag.

In some embodiments, reusability of the versatile storage bag issignificantly improved over prior storage containers due at least inpart to the double-seal construction along the edges of the versatilestorage bag. Multiple welded seams with a double wall spacer allow foradditional strength on the edges of the versatile storage bag.

With healthier living trends from portion control, to toxin/Bisphenol A(BPA) free and waste-free lunch, consumers need a lightweight, durablealternative that allows for daily reuses and washes. Embodiments of aversatile storage bag disclosed herein can address this need and more.For example, it allows customers to carry lots of small snack bags intheir lunch box, purse or brief case, keeping them airtight and fresh,while not requiring a lot of space. Moreover, it allows customers toadhere to bans and trends for waste-free or boomerang lunch, as it caneasily be washed and reused multiple times. Finally, its reusability isnot only convenient, but also saves money, replacing dozens of singleuse bags and containers alike.

These, and other, aspects of the disclosure will be better appreciatedand understood when considered in conjunction with the followingdescription and the accompanying drawings. It should be understood,however, that the following description, while indicating variousembodiments of the disclosure and numerous specific details thereof, isgiven by way of illustration and not of limitation. Many substitutions,modifications, additions and/or rearrangements may be made within thescope of the disclosure without departing from the spirit thereof, andthe disclosure includes all such substitutions, modifications, additionsand/or rearrangements.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings accompanying and forming part of this specification areincluded to depict certain aspects of the disclosure. It should be notedthat the features illustrated in the drawings are not necessarily drawnto scale. A more complete understanding of the disclosure and theadvantages thereof may be acquired by referring to the followingdescription, taken in conjunction with the accompanying drawings inwhich like reference numbers indicate like features and wherein:

FIG. 1 depicts an isometric view of an example embodiment of a versatilestorage bag with a double-locking closure mechanism, double-seal edges,and reinforced corners.

FIG. 2a depicts a diagrammatic representation of a partial, enlargedcross-sectional view of the double-locking closure mechanism of FIG. 1in a non-occluded state, taken generally along the line 2-2 of FIG. 1.

FIG. 2b depicts a diagrammatic representation of a partial, enlargedcross-sectional view of the double-locking closure mechanism of FIG. 2ain an occluded state.

FIG. 3 depicts a diagrammatic representation of a partial, enlargedcross-sectional view of a double-sealed edge of FIG. 1, taken generallyalong the line 3-3 of FIG. 1.

FIG. 4 is a flow chart illustrating an example of a method for making aversatile storage bag according to some embodiments.

FIGS. 5a-5d depict diagrammatic representations of various corner sealprofiles and corresponding stamps or molds used in manufacturing sameaccording to some embodiments.

FIG. 6 depicts a diagrammatic representation of a portion of a toolingfor forming a corner seal of a versatile storage bag according to someembodiments.

FIG. 7 depicts a diagrammatic representation of a pair of L-shapedcorner profiles according to some embodiments.

FIGS. 8a-8d depict diagrammatic representations of different cornerconfigurations according to some embodiments.

FIG. 9 depicts a diagrammatic representation of a partial, enlargedcross-sectional view of a corner portion of one example embodiment of aversatile storage bag, taken generally along the line 4-4 of FIG. 8 d.

FIG. 10 depicts a diagrammatic representation of a tooling for makingdouble seals along the edges of a versatile storage bag according to oneembodiment.

FIG. 11 depicts a diagrammatic representation of a tooling forreinforcing a corner of a double-locking closure mechanism of aversatile storage bag with a particularly configured corner sealaccording to one embodiment.

FIG. 12 depicts a diagrammatic representation of a tooling formanufacturing a versatile storage bag according to one embodiment.

FIG. 13 depicts a diagrammatic representation of a tooling formanufacturing a double-locking closure mechanism of a versatile storagebag according to one embodiment.

DETAILED DESCRIPTION

The disclosure and various features and advantageous details thereof areexplained more fully with reference to the exemplary, and thereforenon-limiting, embodiments illustrated in the accompanying drawings anddetailed in the following description. It should be understood, however,that the detailed description and the specific examples, whileindicating the preferred embodiments, are given by way of illustrationonly and not by way of limitation. Various substitutions, modifications,additions and/or rearrangements within the spirit and/or scope of theunderlying inventive concept will become apparent to those skilled inthe art from this disclosure.

Referring to FIG. 1, versatile storage bag 15 of material 8 according toone non-limiting example embodiment may include first and secondsidewalls 17 and 18, opening 19, ends 13 b, 13 c joined around edges orsides 16 a-16 c, and gusset 13 a defined by seals 12 a and 12 b. Closuremechanism 9 may have first closure element 14 a and second closureelement 14 b on sides 6 and 7. First closure element 14 a and secondclosure element 14 b may extend from first corner 11 a to second corner11 b and may join first and second sidewalls 17, 18 via seam 10 oneither side proximate opening 19. In some embodiments, first closureelement 14 a may include channel 14 a-1 and elongated member 14 a-2. Insome embodiments, second closure element 14 b may include elongatedmember 14 b-1 and channel 14 b-2.

Closure mechanism 9, first and second sidewalls 17, 18, and double-seal12 define storage means interior space 20. As explained below, whenclosure mechanism 9 is fully sealed across opening 19, storage bag 15can provide an airtight seal such that content in interior space 20 maybe maintained for a desired period of time, such as days, months, oryears. In some embodiments, when fully sealed, storage bag 15 canwithstand at least 10 pounds of pressure or higher, for instance, up to35 pounds of pressure. In one embodiment, storage bag 15 can beapproximately 8.5″×4.75″ in size.

FIG. 2a and FIG. 2b respectively depict closure mechanism 9 in anon-occluded state and an occluded state. Referring to FIG. 2 a, channel14 a-1 of first closure element 14 a may have a first locking profilewith arms 1 a-1 b extending from body 1 c, while elongated member 14 b-1of second closure element 14 b may have a second locking profile withstud 2 extending from body 4 c of second closure element 14 a. Stud 2may have a textured surface such as bumps, grooves, or crosswise groovesand may be configured and sized to be securely received by arms 1 a-1 b.The textured surface, size, and/or shape of stud 2 and arms 1 a-1 b maybe configured to provide a tactile sensation and/or audible sensations,such as a series of clicks, as a user draws the fingers along closuremechanism 9 to seal opening 19 of storage bag 15 along the length ofclosure mechanism 9.

First closure element 14 a may further include a third locking profilewith stud 3 extending from body 1 c and second closure element 14 b mayfurther include a fourth locking profile with arms 4 a-4 b extendingfrom body 4 c. Stud 3 may have a textured surface such as grooves andmay be configured and sized to be securely received by arms 4 a-1 b.

As shown in FIG. 2 b, when coupled, first closure element 14 a andsecond closure element 14 b form a double lock for closure mechanism 9,with elongated member 14 b-1 of second closure element 14 b securelyreceived by channel 14 a-1 of first closure element 14 a and elongatedmember 14 a-2 of first closure element securely received by channel 14b-2 of second closure element 14 b in a complementary manner. Thoseskilled in the art will appreciate that the configuration and geometryof first and second closure elements 14 a, 14 b and their respectivelocking profiles may vary from implementation to implementation.Therefore, the example embodiment of first closure element 14 a andsecond closure element 14 b shown in FIG. 2a and FIG. 2b is illustrativeand non-limiting.

Furthermore, in this example embodiment, first closure element 14 a andfirst sidewall 17 may be joined, overlapping edge to edge, or otherwiseaffixed to each other using a thermoplastic weld, a strip of moltenthermoplastic weld material, an adhesive, or any material and/or joiningmethods known to those skilled in the art to form seam 10 along the baseof the first closure element 14 a, as shown in FIG. 2 a. Second closureelement 14 b and second sidewall 18 may be joined, overlapping edge toedge, or otherwise affixed to each other in the same or similar manneralong the base of the second closure element 14 b, as shown in FIG. 2 a.In one embodiment, seam 10 may have a minimum measurement such as 3 mmor approximately 3 mm.

As shown in FIG. 2a and FIG. 2 b, first sealing and locking section 21,22 is disposed on elongated member 14 b-1 of second closure element 14 band second sealing and locking section 23, 24 is disposed on elongatedmember 14 a-2 on first closure element 14 a. Elongated member 14 b-1 ofsecond closure element 14 b and elongated member 14 a-2 of first closureelement 14 a are shown to have the widest pressure point Y¹ and thenarrowest locking point Y². First pressure contact points 5 a and 5 b ofchannel 14 a-1 and second pressure contact points 6 a and 6 b of channel14 b-2 may define a distance of X which is to never be greater than Y²in order to have a proper securement of first and second closureelements 14 a, 14 b to create a waterproof seal. As a non-limitingexample, X may be 0.7 mm and Y² may be 0.8 mm.

As shown in FIG. 1, in some embodiments, first and second sidewalls 17,18 may be joined and double-sealed around three edges or sides 16 a-16c. This may be done using plastic welding. Plastic welding refers to aprocess of uniting polymeric materials, generally with the aid of heator any suitable conductive element. Welding of thermoplastics can beaccomplished by first preparing the surfaces of the materials, applyingheat and/or pressure to the materials, and allowing the materials tocool. Other welding methods may also be used.

Referring to FIG. 3, in some embodiments, double welded seams or seals12 a, 12 b may have a minimum width of Z. In some embodiment,reinforcement section or gusset 13 a between double seals 12 a and 12 bmay have a width of W where W is approximately no less than three timesZ such that double seals 12 a and 12 b formed on three sides of storagebag 15 are parallel or substantially parallel to each other as shown inFIG. 1. As a non-limiting example, Z may be 0.3 mm and W may be 0.9 mmor more. In one embodiment, gusset 13 a may have a width of 2 mm orapproximately 2 mm.

FIG. 4 is a flow chart illustrating an example of a method for making aversatile storage bag according to some embodiments. In someembodiments, method 40 may include creating a portion having a firstclosure element (41), creating a second portion (42), and joining thefirst portion and the second portion to create a first sidewall with thefirst closure element (43). The first closure element may have a channeland an elongated member similar to channel 14 a-1 and elongated member14 a-2 described above with reference to FIGS. 2a and 2 b.

These steps may be repeated to create a second sidewall with a secondclosure element. The closure element may have a channel and an elongatedmember similar to elongated member 14 b-1 and channel 14 b-2 describedabove with reference to FIGS. 2a and 2 b. Since the second closureelement may be complementary to the first closure element, the same tooland/or mold may be used to create both the first portion having thefirst closure element and a complementary first portion having thesecond closure element that is complementary to the first closureelement (44). Likewise, the same tool and/or mold may be used to makethe second portion and a complementary second portion. The complementaryfirst portion may be joined with the complementary second portion in thesame or similar manner to create the second sidewall with the secondclosure element (45).

The first sidewall and the second sidewall may be aligned (46) such thatthe first closure element and the second closure element together canform a double-locking closure mechanism similar to closure mechanism 9described above. Once properly aligned, a double-seal such asdouble-seal 12 described above can be formed (e.g., using a sealingtool) along three sides of the first and second sidewalls, leaving anopening through the double-locking closure mechanism (47).

If desired, corner seals can be formed at the corners to reinforce thedouble-locking closure mechanism (49). Specifically, a first corner sealmay be created at a first corner of the first sidewall and the secondsidewall, the first corner seal reinforcing a first end of thedouble-locking closure mechanism and a second corner seal may be createdat a second corner of the first sidewall and the second sidewall, thesecond corner seal reinforcing a second end of the double-lockingclosure mechanism.

In some embodiments, the first portion, the second portion, and theircomplementary first and second portions may be made of a thermoplasticmaterial. Examples of suitable thermoplastic materials may includepolypropylene (PP), ethylene vinyl acetate (EVA), polyethylene (PE),metallocene-polyethylene (mPE), low density polyethylene (LDPE), linearlow density polyethylene (LLDPE), ultra-low density polyethylene(ULDPE), biaxially-oriented polyethylene terephthalate (BPET), highdensity polyethylene (HDPE), polyethylene terephthalate (PET), recycledpolyethylene terephthalate (RPET), polyethylene vinyl acetate (PEVA)among other polyolefin plastomers and combinations and blends thereof.Other additives such as colorants, slip agents, and antioxidants,including for example talc, oleamide or hydroxyl hydrocinnamate may alsobe added as desired.

Embodiments of a versatile storage bag disclosed herein preferably aremade of a food grade material which is Food and Drug Administration(FDA) approved, Bisphenol A (BPA) free, flexible, freezer safe (e.g.,cold resistant up to the operating temperature of a typical freezer suchas 20 degrees Fahrenheit), heat resistant and dishwasher safe (e.g.,heat resistant up to the operating temperature of a typical dishwashersuch as 200 degrees Fahrenheit), lead-free, PVC-free, and/or hand washsafe.

In some embodiments, the first portion, the second portion, and theircomplementary first and second portions may be made of the same ordifferent thermoplastic material(s). As an example, first sidewall 17and second sidewall 18 of storage bag 15 shown in FIG. 1 may be made ofa first type of thermoplastic material while double-locking closuremechanism 9 may be made of a second type of thermoplastic material. Insome embodiments, the first type of thermoplastic material may have athickness of about 0.25 mm to 0.35 mm, preferably about 0.30 mm. Thesecond type of thermoplastic material may have the same or differentthickness.

In some embodiments, a thermoplastic material may be EVA or a PEVA blendof EVA and PE. The PEVA blend may comprise 1% to 10% of PE and 99% to90% of EVA. The ratio of EVA to PE in a PEVA blend determines itsstiffness/flexibility. The stiffness of the material may affect howeasily the double-locking closure mechanism may be closed/opened. Thus,the ratio of EVA to PE in a PEVA blend may vary from application toapplication, depending upon what degree of flexibility/stiffness isdesired. The heat resistance property of a PEVA blend may be manipulatedin a similar manner. For example, a PEVA blend with 99% EVA and 1% PEmay have high tear resistance and heat resistance, while a PEVA blendwith 70% EVA and 30% PE may be softer, but with less tear resistance andless heat resistance. In some embodiments, a PEVA blend of 90% EVA and10% PE may provide a non-chlorine PVC alternative to food grade storagebags as PVC is not a food grade material. PEVA bonds to another materialthat is made out of either PE or EVA. Thus, some embodiments of aversatile storage bag disclosed herein can be formed from anycombination of PEVA, EVA, and PE materials.

In some embodiments, an organic thermoplastic polymer such as polyetherether ketone (PEEK) may be used. PEEK melts around 343° C. (662° F.) andit is FDA approved food grade material. Since it is relatively stiff, ablend of PEEK including another material or materials may be used. ForPEEK, the thinnest laminate thickness the industry currently has is 1millimeter thick. The thinnest silicon laminate available is eventhicker than the thinnest PEEK laminate. In some embodiments, a blend orcomposition including a 50% PEEK, a 48% EVA, and a 2% PE material may beused. In another blend, a ratio can be 40:20:40 with PEEK added for highheat resistance, EVA added for flexibility and durability, and PE addedfor flexibility.

In dishwasher safe embodiments, 100% silicon material or a differentsuitable blend or a different suitable material may be used. Injectionmolding processes may be used in manipulating a silicon material.

In some embodiments, a versatile storage bag disclosed herein can beformed from high-density polyethylene (HDPE) or polyethylenehigh-density (PEHD) which is a polyethylene thermoplastic. HDPE may bemade into film (sheets) and bonded to silicon or other plastics or toacrylic etc.

In some embodiments, aesthetics (the look and feel) of a versatilestorage bag disclosed herein may be varied by using and/or blendingcertain materials. For example, the first type of thermoplastic materialmay be formed such that first sidewall 17 and second sidewall 18 ofstorage bag 15 shown in FIG. 1 are partially transparent or appeartranslucent. Alternatively, first and second sidewalls 17, 18 may bemade opaque by adding a coloring agent to the blend or by changingratios of materials in the blend. Likewise, double-locking closuremechanism 9 may be made transparent, opaque, translucent, and/orcolored.

As an example, a thermoplastic resin may be directed through anextrusion tool having a mold for forming the first closure element. Theextruded part may be cut to size to create the first portion. Thecomplementary first portion may be extruded in the same or similarmanner. In some embodiments, the first portion (with the first closureelement) and the complementary first portion (with the second closureelement) may be extruded primarily of molten EVA with various amounts ofslip component, colorant, and talc additives in a separate process.

In some embodiments, the first portion and the complementary firstportion may be the same or substantially the same. In some embodiments,the first portion may have a height different than a height of thecomplementary first portion. For example, first closure element 14 a onside 6 may be taller or shorter than second closure element 14 b on side7.

The same or a different thermoplastic material may be directed through adifferent extrusion tool (e.g., casting film machine) having a mold forforming a sheet or sheets (multi-ply) and then cut to size and/or shapeto form the second portion. The second portion may have a first flatsurface that eventually becomes part of the outside of the storage bagthus made and a second flat surface that eventually forms part of theinterior space (e.g., interior space 20 shown in FIG. 1). In someembodiments, the first and second surfaces of the second portion may bethe same or substantially the same. In some embodiments, the first andsecond surfaces of the second portion may be different. For example, thefirst and second surfaces of the second portion may be textured,colored, or otherwise treated differently. In some embodiments, thecomplementary second portion may be the same or substantially the sameas the second portion. Referring to FIG. 1, in some embodiments, one orboth sidewalls 17, 18 may be embossed or otherwise textured with apattern, such as a diamond pattern, on one or both surfaces spacedbetween bottom edge 16 b and closure mechanism 9.

Once they are made, the first portion and the second portion can bealigned and joined to form the first sidewall with the first closureelement as described above. Likewise, the complementary first portionand the complementary second portion can be aligned and joined to formthe second sidewall with the second closure element. In someembodiments, radio frequency (RF) welding may be used. RF weldingapplies electricity as a heat element to melt a positive and a negativecharge. RF welding is considered the least expensive type of welding andthe fastest one to manufacture the storage bag described above. Othertools such as a sealing tool may be used.

The first sidewall and the second sidewall are then aligned and asealing tool may be applied to create a double-seal along three sides ofthe first sidewall and the second sidewall, leaving an opening throughthe double-locking closure mechanism. To reinforce, a corner seal may becreated (e.g., using RF welding via a heat-molded stamp) at each cornerof the double-locking closure mechanism. Each corner seal is sized toaccommodate the height, width, and depth of the ends of thedouble-locking closure mechanism. As an example, a corner seal may be 3millimeters in height, 4 to 4½ millimeters in depth, and 9 millimetersin width to accommodate the width of the double-locking closuremechanism such that the ends of the double-locking closure mechanism aresecurely sealed. The thickness of the corner seals may be the same asthe thickness of the double-locking closure mechanism when it is closed.

Referring to FIG. 1, in some embodiments, corner seals 11 c, 11 d mayhave a particular profile created with a corresponding tooling for aspecific application. FIGS. 5a-5d depict diagrammatic representations ofvarious corner seal profiles and corresponding molds used inmanufacturing same according to some embodiments. More specifically,FIG. 5a depicts an example of half-moon corner seal profile 51 andcorresponding half-moon shaped mold or stamp 52. FIG. 5b depicts anotherexample of half-elliptical corner seal profile 53 and corresponding moldor stamp 54. FIG. 5c depicts yet another example of triangular cornerseal profile 55 and corresponding mold or stamp 56. FIG. 4d depicts anexample of square corner seal profile 57 and corresponding mold or stamp58. Numerous other corner seal profiles are also possible. Preferably,corner seals 11 c, 11 d are formed to have half-moon corner seal profile51. An example portion of half-moon shaped mold or stamp 52 is shown inFIG. 6.

Referring to FIG. 6, a corner seal may be created using stamp or mold 60having half-moon shaped cavity 65 arising out of flat surface 61. Inthis example, the back side of half-moon shaped cavity 65 is cutoff toshow a cross-sectional view of mold 60. Mold 60 may be referred to as atop plate. In some embodiments, mold 60 may be part of a tool such ascorner seal reinforcement mold portion 112 of tool 110 shown in FIG. 11.When positioned on top of a base plate having a flat surface such astable 62, mold 60 can create space 63 having a corner seal profile suchas half-moon corner seal profile 51 shown in FIG. 5 a. In an RF toolingprocess, the top plate is kept at one charge and the base plate is keptat a different charge. The RF tooling process passes the charge throughthe material. Referring to FIG. 1, to form half-moon corner seal 11 c,arc-shaped stamp 60 may be pressed down onto corner 11 a where bothsidewalls 17, 18 meet an end of double-locking closure mechanism 9. Thepressure pushes the heated material to fill space 63, forming a bubble.In some embodiments, additional material may be injected or otherwiseprovided to fill space 63, ensuring a good seal. This stamping processof the corners (e.g., corners 11 a, 11 b shown in FIG. 1) creates astrong, permanent bonding between the ends of the first and secondclosure elements, the seam between the double-locking closure mechanismand the sidewalls, and the ends of the double-seal, some examples ofwhich are illustrated in FIGS. 8a -8 d.

As a result of the stamping process, these corners may have a particularcorner profile such as L-shaped corner profile 75 a, 75 b shown in FIG.7. Depending upon implementation details, other corner profiles may alsobe possible, as exemplified in FIGS. 8a -8 d.

FIGS. 8a-8d illustrate various corner profiles that may be formed at acorner of a versatile storage bag (e.g., corner 11 a of versatilestorage bag 15 shown in FIG. 1) according to some embodiments.

In FIG. 8 a, a partial view of one embodiment of versatile storage bag15 is shown. In this example, double-locking closure mechanism 9 hasfirst lock 85 a (e.g., when channel 14 a-1 of first closure element 14 ais interlocked with elongated member 14 b-1 of second closure element 14b, as shown in FIG. 2b ) and second lock 85 b (e.g., when elongatedmember 14 a-2 of first closure element 14 a is interlocked with channel14 b-2 of second closure element 14 b, as shown in FIG. 2b ). Corner 80a is formed (e.g., via a stamping process described above) to securelyseal and permanently bond the ends of first lock 85 a and second lock 85b of double-locking closure mechanism 9, seam 10, and the ends of seals12 a, 13 b, further reinforcing gusset 13 a. In this example, corner 80a has a box-shaped (rectangle or square) corner profile.

In FIG. 8 b, a partial view of one embodiment of versatile storage bag15 is shown. In this example, corner 80 b has an L-shaped cornerprofile, with ends 86 a, 86 b of first lock 85 a and second lock 85 bextending into corner 80 b beyond seal 12 b. In some cases, the L-shapedcorner profile of corner 80 b may be caused by a slight shifting ofversatile storage bag 15 during manufacturing, for instance, as thecorner stamping tool is used repeatedly and/or when versatile storagebag 15 may not be positioned inside an edge tool correctly. Due tocontinuous use of the tools, heat may be generated, causing expansion ofthe tools which, in turn, affects the precision profile of corner 80 b.However, as illustrated in FIG. 8 b, the L-shaped corner profile ofcorner 80 b is within the manufacturing tolerance, allowing corner 80 bto securely seal and permanently bond ends 86 a, 86 b of first lock 85 aand second lock 85 b of double-locking closure mechanism 9, seam 10, andthe ends of seals 12 a, 13 b, further reinforcing gusset 13 a.

In some embodiments, the ends of first lock 85 a and second lock 85 b ofdouble-locking closure mechanism 9 may be further reinforced via acorner seal. This is further illustrated in FIGS. 8c and 8 d.

In FIG. 8 c, corner seal 87 may be formed simultaneously with corner 80c or in a separate process after corner 80 c is stamped down. Asdescribed above and illustrated in FIGS. 5a -5 d, such a corner seal mayhave various shapes and sizes. In this example, corner seal 87 is formedwith a triangular stamp or mold. One of the advantages of this cornerseal reinforcement feature is that it can avoid micro-fissures at thelink or seal point between sides 6 and 7 of versatile storage bag 15.Such micro-fissures can cause leaking. Such leaking can be presented byforming corner seal 87 around the ends of first lock 85 a and secondlock 85 b, as illustrated in FIG. 8 c.

FIG. 8d illustrates another example of corner seal 89. Corner seal 89may have a half-moon profile with a depth “T” based on a width “S”defined by first lock 85 a and second lock 85 b. For example, “T” may bedefined as “≥60% of S.” In some embodiments, “S” may be 7 mm orapproximately 7 mm.

A partial, enlarged cross-sectional view of corner seal 89, takengenerally along the line 4-4 of FIG. 8 d, is shown in FIG. 9. In thisexample, corner seal 89 may have a cross-sectional height of “H” definedby a tool such as arc-shaped stamp 60 shown in FIG. 6. In oneembodiment, “H” may be defined by space 63 of arc-shaped stamp 60. FIG.9 shows another embodiment of studs 2 and 3 having a shape and/ortexture that is different from the example shown in FIGS. 2a and 2 b.

FIG. 10 depicts a diagrammatic representation of a tooling for makingdouble seals along the edges of a versatile storage bag according to oneembodiment. In this example, tool 100 can be made of metal and includedouble-edge seam mold portion 102 having first and second edge sealmolds 105 a, 105 b. Tool 100 may further include corner stamp area 104.In one embodiment, tool 100 may be used to create seals 12 a, 12 b,gusset 13 a, and corner 80 a shown in FIG. 8 a. To create a corner seal,a separate machine or device such as tool 110 shown in FIG. 11 may beused.

FIG. 11 depicts a diagrammatic representation of a tooling forreinforcing a corner of a double-locking closure mechanism of aversatile storage bag with a particularly configured corner sealaccording to one embodiment. In this example, tool 110 includes cornerseal reinforcement mold portion 112 having a half-moon, bowl, ordome-like profile.

In some embodiments, a single machine or device may be used tosimultaneously create the seals (e.g., seals 12 a, 12 b), the gusset(e.g., gusset 13 a), the corners (e.g., corners 11 a, 11 b), and thecorner seals (e.g., corner seals 11 c, 11 d). FIG. 12 depicts adiagrammatic representation of such a device according to oneembodiment. In this example, tool 120 includes double-edge seam moldportion 102 having first and second edge seal molds 105 a, 105 b similarto those of tool 100 described above for forming the seals and thegusset as described above. Tool 120 further includes corner stamp area124 having corner seal reinforcement feature mold portion 122 forforming corners with corner seals as described above.

FIG. 13 depicts a diagrammatic representation of a tooling formanufacturing a double-locking closure mechanism of a versatile storagebag according to one embodiment. In this example, tool 130 may includemetal plate 131. Plate 131 has extrusion opening 132 with shaped formsor molds 134, 13 a, and 136 b. As an example, place 131 may be used toform first and second closure elements 14 a, 14 b described above. Forexample, an extrusion machine pushes or pumps a molten material from oneside of extrusion opening 132 to form first and second closure elements14 a, 14 b on the other side of extrusion opening 132. The extrusionprocess is known to those skilled in the art and thus is not furtherdescribed herein. Other processes such as injection molding may also beused to form closure elements 14 a, 14 b.

Although the invention has been described with respect to specificembodiments thereof, these embodiments are merely illustrative, and notrestrictive of the invention. The description herein of illustratedembodiments of the invention, including the description in the Summary,is not intended to be exhaustive or to limit the invention to theprecise forms disclosed herein (and in particular, the inclusion of anyparticular embodiment, feature or function within the Summary is notintended to limit the scope of the invention to such embodiment, featureor function). Rather, the description is intended to describeillustrative embodiments, features and functions in order to provide aperson of ordinary skill in the art context to understand the inventionwithout limiting the invention to any particularly described embodiment,feature or function, including any such embodiment feature or functiondescribed in the Summary. While specific embodiments of, and examplesfor, the invention are described herein for illustrative purposes only,various equivalent modifications are possible within the spirit andscope of the invention, as those skilled in the relevant art willrecognize and appreciate. For example, color can be used on tabs at topof the double-locking closure mechanism to help create visualdistinction from the rest of the storage bag, making it easier toidentify the opening and unlock. Color can also be applied to the mainstorage element of the bag, in whole or part, to make it easier to seethe contents and/or to distinguish from single use, disposable stylebags. In addition, color can be used as an organizing element forpacking food, identifying person, or keeping distinct for certain foodsto address food allergies.

As indicated, these modifications may be made to the invention in lightof the foregoing description of illustrated embodiments of the inventionand are to be included within the spirit and scope of the invention.Thus, while the invention has been described herein with reference toparticular embodiments thereof, a latitude of modification, variouschanges and substitutions are intended in the foregoing disclosures, andit will be appreciated that in some instances some features ofembodiments of the invention will be employed without a correspondinguse of other features without departing from the scope and spirit of theinvention as set forth. Therefore, many modifications may be made toadapt a particular situation or material to the essential scope andspirit of the invention.

Reference throughout this specification to “one embodiment”, “anembodiment”, or “a specific embodiment” or similar terminology meansthat a particular feature, structure, or characteristic described inconnection with the embodiment is included in at least one embodimentand may not necessarily be present in all embodiments. Thus, respectiveappearances of the phrases “in one embodiment”, “in an embodiment”, or“in a specific embodiment” or similar terminology in various placesthroughout this specification are not necessarily referring to the sameembodiment. Furthermore, the particular features, structures, orcharacteristics of any particular embodiment may be combined in anysuitable manner with one or more other embodiments. It is to beunderstood that other variations and modifications of the embodimentsdescribed and illustrated herein are possible in light of the teachingsherein and are to be considered as part of the spirit and scope of theinvention.

In the description herein, numerous specific details are provided, suchas examples of components and/or methods, to provide a thoroughunderstanding of embodiments of the invention. One skilled in therelevant art will recognize, however, that an embodiment may be able tobe practiced without one or more of the specific details, or with otherassemblies, methods, components, materials, parts, and/or the like. Inother instances, well-known structures, methods, components, materials,or operations are not specifically shown or described in detail to avoidobscuring aspects of embodiments of the invention. While the inventionmay be illustrated by using a particular embodiment, this is not anddoes not limit the invention to any particular embodiment and a personof ordinary skill in the art will recognize that additional embodimentsare readily understandable and are a part of this invention.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having,” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,product, article, or apparatus that comprises a list of elements is notnecessarily limited only those elements but may include other elementsnot expressly listed or inherent to such process, product, article, orapparatus.

Furthermore, the term “or” as used herein is generally intended to mean“and/or” unless otherwise indicated. As used herein, including theclaims that follow, a term preceded by “a” or “an” (and “the” whenantecedent basis is “a” or “an”) includes both singular and plural ofsuch term, unless clearly indicated within the claim otherwise (i.e.,that the reference “a” or “an” clearly indicates only the singular oronly the plural). Also, as used in the description herein and throughoutthe claims that follow, the meaning of “in” includes “in” and “on”unless the context clearly dictates otherwise. The scope of thedisclosure should be determined by the following claims and their legalequivalents.

What is claimed is:
 1. A storage bag, comprising: a first sidewall; asecond sidewall; a double-locking closure mechanism comprising a firstclosure element extending along the first sidewall and a second closureelement extending along the second sidewall, the first closure elementhaving a channel and an elongated member extending along a base of thefirst closure element, the second closure element having an elongatedmember and a channel extending along a base of the second closureelement; a double-seal along three sides of the first sidewall and thesecond sidewall, leaving an opening through the double-locking closuremechanism, the double-seal comprising a gusset; a first corner seal at afirst corner of the first sidewall and the second sidewall, the firstcorner seal reinforcing a first end of the double-locking closuremechanism; and a second corner seal at a second corner of the firstsidewall and the second sidewall, the second corner seal reinforcing asecond end of the double-locking closure mechanism.
 2. The storage bagof claim 1, wherein the first sidewall has a thickness of about 0.25 mmto 0.35 mm.
 3. The storage bag of claim 1, wherein the first corner sealis sized to accommodate ends of the first closure element and the secondclosure element.
 4. The storage bag of claim 1, wherein the first cornerhas an L-shaped corner profile.
 5. The storage bag of claim 4, whereinthe first corner seal has a half-moon shaped profile.
 6. The storage bagof claim 1, wherein the double-seal has a width and wherein the gussetis approximately no less than three times the width.
 7. The storage bagof claim 1, wherein the gusset has a width of 2 mm or approximately 2mm.
 8. The storage bag of claim 1, wherein the first and secondsidewalls comprise a first material and the first and second closureelements comprise a second material.
 9. The storage bag of claim 8,wherein the first material is a blend of approximately 90% or lessethylene vinyl acetate (EVA) and approximately 10% or less polyethylene(PE).
 10. The storage bag of claim 8, wherein the first material and thesecond material are same or different.
 11. A storage bag, comprising: afirst sidewall having a first portion and a second portion, the firstportion having a first closure element, the first closure element havinga channel and an elongated member extending along a base of the firstclosure element, the second portion having a flat or substantially flatsurface, the first portion and the second portion overlapped edge toedge along the base of the first closure element; a second sidewallhaving a complementary first portion and a complementary second portion,the complementary first portion having a second closure element, thesecond closure element having an elongated member and a channelextending along a base of the second closure element, the complementarysecond portion having a flat or substantially flat surface, thecomplementary first portion and the complementary second portionoverlapped edge to edge along the base of the second closure element,the complementary first portion of the second sidewall beingcomplementary to the first portion of the first side wall, thecomplementary second portion of the second sidewall being complementaryto the second portion of the first side wall; two seals along threesides of the first sidewall and the second sidewall, the first sidewalland the second sidewall overlapped edge to edge on the three sides; afirst corner seal at a first corner of the first sidewall and the secondsidewall; and a second corner seal at a second corner of the firstsidewall and the second sidewall.
 12. The storage bag of claim 11,wherein the first portion of the first sidewall and the complementaryfirst portion of the second sidewall are of same size or substantiallythe same size.
 13. The storage bag of claim 11, wherein the firstportion of the first sidewall has a height that is different than aheight of the complementary first portion of the second sidewall. 14.The storage bag of claim 11, wherein the second portion of the firstsidewall has a first surface and a second surface that have same orsubstantially the same surface treatment.
 15. The storage bag of claim11, wherein the second portion of the first sidewall has a first surfaceand a second surface that have different surface treatments.
 16. Thestorage bag of claim 11, wherein the two seals are parallel orsubstantially parallel to one another, with a gusset between the twoseals.
 17. The storage bag of claim 16, wherein a seal of the two sealshas a width and wherein the gusset is approximately three times or morethan three times the width of the seal.
 18. The storage bag of claim 11,wherein the first and second sidewalls comprise a first material and thefirst and second closure elements comprise a second material.
 19. Thestorage bag of claim 18, wherein the first material is a blend ofapproximately 90% or less ethylene vinyl acetate (EVA) and approximately10% or less polyethylene (PE).
 20. The storage bag of claim 18, whereinthe first material and the second material are same or different.